System and method for battery cell balancing
Without battery cell balancing, voltages of multiple series-connected battery cells may quickly become out of balance, which causes some cells of the battery to deteriorate faster than others, and reduces the life cycle of the battery. Embodiments of the present invention address this problem by providing a system for balanced charging of multiple series-connected battery cells. The system includes resistors that are selectably and electrically coupled in parallel with respective battery cells via activation and deactivation of respective switches. The system also includes a control unit that is configured to determine a battery cell having a lowest voltage among the battery cells, and to activate and deactivate the switches as a function of differences in voltages between the voltage of the lowest battery cell and voltages of each of the other battery cells, thus, providing balanced charging of the multiple series-connected battery cells.
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An uninterruptible power supply (UPS), also known as a continuous power supply (CPS) or battery backup, is a device that maintains a continuous supply of electric power to connected equipment, such as, for example, computers or telecommunications equipment, by supplying power from a separate source when a normal power source (e.g., AC wall outlet) is interrupted or not available. A UPS differs from an auxiliary power supply or standby generator, which does not provide instant protection from a momentary power interruption.
A UPS can be used to provide uninterrupted power to equipment for a certain duration, for example, thirty minutes, until a generator can be turned on or until the normal power source is restored. Integrated systems that have UPS and standby generator components are often referred to as emergency power systems. A UPS system may remain idle until a power failure occurs and then quickly switch from utility power to its own power source, or may continuously power the protected equipment from its energy reserves stored in a battery while simultaneously replenishing its reserves from another power source. When the battery's energy reserves are depleted, or partially drained, the battery will need to be recharged. With batteries that contain a number of serially-connected battery cells, draining and recharging of the battery often results in a voltage imbalance among the cells.
SUMMARY OF THE INVENTIONOne embodiment of the present invention is a system for balanced charging of multiple series-connected battery cells. The system includes resistors that are selectably electrically coupled in parallel with respective battery cells among the multiple series-connected battery cells, where the coupling is accomplished through activation and deactivation of respective switches. The system also includes a control unit that is configured to determine a battery cell having a lowest voltage among the battery cells. That battery cell is referred to as the lowest battery cell. The control unit is further configured to activate and deactivate the switches as a function of differences in voltages between the voltage of the lowest battery cell and voltages of each of the other battery cells, where the activation and deactivation of the switches provides balanced charging of the multiple series-connected battery cells.
The foregoing will be apparent from the following more particular description of example embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating embodiments of the present invention.
A description of example embodiments of the invention follows.
Differences in voltages among series-connected battery cells can lead to many problems, including premature cell degradation, safety hazards, and reduced battery capacity. Some battery cells with higher voltages, for example, such as voltages that are higher than a manufacturer's suggested limit, may degrade faster as a result of the cells being overcharged. Overcharged cells pose safety hazards, including explosion and fire. To prevent overcharging, many charging systems include a safety protection circuit to terminate charging if any one of the battery cells reaches a certain limit. When cells are unbalanced, such a termination can cause the charging of the other cells to terminate prematurely, resulting in reduced capacity of the battery. A battery with reduced capacity will not provide power for as long as it should, and repeated charging and discharging of the battery may exacerbate the problem, resulting in a reduced life cycle of the battery. Thus, balanced charging of series-connected battery cells can significantly increase the useful life cycle of the battery. The embodiments disclosed herein address this issue of balanced charging.
One embodiment of the present invention is a system for balanced charging of multiple series-connected battery cells. The system includes resistors that are selectably electrically coupled in parallel with respective battery cells among the multiple series-connected battery cells, where the coupling is accomplished through activation of respective switches, and decoupling is accomplished through deactivation of the respective switches. The system also includes a control unit that is configured to determine a battery cell having a lowest voltage among the battery cells (“lowest battery cell”). The control unit is further configured to activate and deactivate the switches as a function of differences in voltages between the voltage of the lowest battery cell and voltages of each of the other battery cells, where the activation and deactivation of the switches provides balanced charging of the multiple series-connected battery cells.
In other embodiments, the control unit may activate or deactivate each of the switches based on respective differences in voltage between the voltage of the determined lowest battery cell and the voltage of each respective battery cell. Such activation or deactivation of each switch may be based on whether the difference in voltage between the determined lowest battery cell and the respective battery cell exceeds a threshold value. In embodiments that activate or deactivate switches based on a threshold value, the control unit may be configured to adjust the threshold value based on trends of voltage differences over time or based on the voltage of the lowest battery cell at any one time. The control unit may also be configured to determine the lowest battery cell and update the activation states of the switches according to a time interval, and may further adjust the time interval dynamically based on trends of voltage differences over time.
The control unit, in some embodiments, may be configured to disable charging of the battery cells in an event any one of the battery cells reaches a maximum voltage limit, or in an event the total voltage of all the battery cells reaches a maximum voltage limit. Embodiments may also include one or more temperature sensors coupled to the control unit and may be configured to disable charging of the battery cells in an event the temperature of any one of the battery cells, or the ambient temperature around the battery cells, exceeds a temperature limit. It should be noted that the control unit may include an analog-to-digital converter, processor, and addressing logic, may be active during at least portion of charging of the battery cells, and may be configured to disable charging of the battery cells during active use of the cells.
Former approaches for balanced battery charging include setting a high voltage limit for the cells of a battery (e.g., 3.4V or 90% of the manufacturer suggested absolute single cell voltage limit), where if any one cell is exceeds the limit, a cell balancing circuit for the cell is turned on to split and reduce the battery charge current for that cell. This approach performs cell balancing on the strongest cells, and after the strongest cell reaches its 100% absolute single cell voltage limit, the charger has to be shut down. At the end of charging, however, the other cells may still not have reached a balanced level.
Embodiments of the present invention overcome the problems of former approaches by using a delta value as balancing “ruler.” During charging of the battery cells, differences between the voltages of the cells and the voltage of the lowest cell (i.e., weakest cell) are determined. For each cell, if the voltage difference is higher than the delta value, then the charge current being applied to that cell is reduced. Each time the differences are determined, it may be a different cell that is the weakest cell due to, for example, hardware limitations or random charge current variations.
The delta value voltage limit may be variable and can be changed at various stages to achieve better control and cell balancing. For example, a larger delta may be used at the beginning of the charging process, and smaller delta values may be used as cell voltages increase. This dynamic changing of the delta value during the cell balancing process not only improves cell balance circuit on/off judgment, but also provides greater flexibility in controlling the cell balancing levels based on real-time information. Because the difference in voltages between the cells is continually monitored and compared to the delta value, this approach not only reduces the chance of the cells being unbalanced when charging is complete (e.g., when any one cell reaches an absolute volt limit), but also helps to reduce cell impedance and, as a result, total charging time is reduced. Additionally, this approach may be implemented using a low-end 8-bit microprocessor with a 10-bit A/D channel. When the cell voltage differences are determined, the approach can control the switches by setting a number of “balancing” bits all at once in a register to turn on/off respective balancing circuits. This reduces the impact from a surge reading due to sudden changes in current.
The embodiments of the present invention may also stop the charging process upon detecting battery discharging activities, which prevents an unexpected reverse situation in which more current would be drawn from the weakest cell as compared to the other cells. Additionally, to protect cells from being overcharged, the embodiments may include various “firewalls” that shutdown the charger if, for example, any of the following conditions are met: (1) any one cell reaches an absolute voltage limit, (2) total battery voltage exceeds a certain limit (e.g., number of cells*ideal high limit voltage*1.05), or (3) ambient temperature has reached or exceeded 60 degrees Celsius.
While this invention has been particularly shown and described with references to example embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention encompassed by the appended claims.
It should be understood that the diagrams of
The disclosed embodiments can be applied to any UPS topology, such as off-line, line interactive, or double conversion. An example UPS topology is illustrated in
The embodiments presented herein are illustrated with respect to such a UPS application, but it should be understood that the embodiments can be applied to other applications with a battery having multiple series-connected battery cells. Further, the embodiments disclosed herein may be used for balanced charging of a battery that contains, for example, four Lithium Iron Phosphate (LiFePO) cells made by a battery manufacturer, such as A123, but is not limited to such LiFePO cells. One of ordinary skill in the art would appreciate that the embodiments disclosed herein may be applied to other kinds of battery cells, or batteries with more or fewer cells, while still achieving good cell balancing results.
Claims
1. A system for balanced charging of multiple series-connected battery cells, the system comprising:
- resistors being selectably electrically coupled in parallel with respective battery cells, among the multiple series-connected battery cells, through activation and deactivation of respective switches; and
- a control unit configured to determine a battery cell having a lowest voltage among the multiple series-connected battery cells, resulting in a determined lowest battery cell, and configured to activate and deactivate each of the respective switches as a function of a respective difference in voltage between the lowest voltage of the determined lowest battery cell and a respective voltage of each respective battery cell to provide balanced charging of the multiple series-connected battery cells during a charging process, the control unit further configured to activate or deactivate the respective switches by setting a number of balancing bits all at once based on each respective difference in voltage between the lowest voltage of the determined lowest battery cell and each respective voltage of each respective battery cell, the control unit still further configured to activate a respective switch of the respective switches in an event the respective difference in voltage between the lowest voltage of the determined lowest battery cell and the respective voltage of the respective battery cell exceeds a threshold value, wherein the threshold value is a larger threshold value at a beginning of the charging process and a smaller threshold value as cell voltages increase.
2. A system as in claim 1 wherein the control unit is configured to adjust the threshold value based on trends of voltage differences over time.
3. A system as in claim 1 wherein the control unit is configured to adjust the threshold value based on the voltage of the determined lowest battery cell.
4. A system as in claim 1 wherein the control unit is configured to determine the lowest battery cell and update the activation states of the switches according to a time interval.
5. A system as in claim 4 wherein the control unit is further configured to adjust the time interval dynamically based on trends of voltage differences over time.
6. A system as in claim 1 wherein the control unit is configured to disable charging of the battery cells in an event one of the battery cells reaches a first maximum voltage limit or in an event a total voltage of all the battery cells reaches a second maximum voltage limit.
7. A system as in claim 1 further including a temperature sensor coupled to the control unit and configured to disable charging of the battery cells in an event the temperature of at least one of the battery cells or the ambient temperature around the battery cells exceeds a temperature limit.
8. A system as in claim 1 wherein the control unit is configured to disable charging of the battery cells during active use of the battery cells.
9. A system as in claim 1 wherein the control unit is active during a portion of charging of the battery cells.
10. A system as in claim 1 wherein the control unit includes an analog-to-digital converter, processor, and addressing logic.
11. A method of balanced charging of multiple series-connected battery cells, the method comprising:
- selectively electrically coupling resistors in parallel with respective battery cells, among the multiple series-connected battery cells, using respective switches;
- determining a battery cell having a lowest voltage among the multiple series-connected battery cells, resulting in a determined lowest battery cell;
- determining a respective difference in voltage between the lowest voltage of the determined lowest battery cell and a respective voltage of each respective battery cell; and
- activating and deactivating the respective switches as a function of each respective difference in voltage to provide balanced charging of the multiple series-connected battery cells during a charging process, wherein activating and deactivating the respective switches includes: activating or deactivating each of the respective switches by setting a number of balancing bits all at once based on each respective difference in voltage between the lowest voltage of the determined lowest battery cell and each respective voltage of each respective battery cell; and activating a respective switch of the respective switches in an event the respective difference in voltage between the lowest voltage of the determined lowest battery cell and the respective voltage of the respective battery cell exceeds a threshold value, wherein the threshold value is a larger threshold value at a beginning of the charging process and a smaller threshold value as cell voltages increase.
12. A method as in claim 11 further including adjusting the threshold value based on trends of voltage differences over time.
13. A method as in claim 11 further including adjusting the threshold value based on the voltage of the determined lowest battery cell.
14. A method as in claim 11 wherein determining the lowest battery cell, determining the respective differences in voltage, and activating and deactivating the switches occur according to a time interval.
15. A method as in claim 14 further including dynamically adjusting the time interval based on trends of voltage differences over time.
16. A method as in claim 11 further including disabling charging of the battery cells in an event one of the battery cells reaches a first maximum voltage limit or in an event a total voltage of all the battery cells reaches a second maximum voltage limit.
17. A method as in claim 11 further including:
- measuring a temperature of at least one of the battery cells or the ambient temperature around the battery cells; and
- disabling charging of the battery cells in an event the temperature of at least one of the battery cells or the ambient temperature around the battery cells exceeds a temperature limit.
18. A method as in claim 11 further including disabling charging of the battery cells during active use of the battery cells.
19. A system for balanced charging of multiple series-connected battery cells, the system comprising:
- means for selectably electrically coupling resistors in parallel to respective battery cells;
- means for determining a battery cell having a lowest voltage among the multiple series-connected battery cells, resulting in a determined lowest battery cell;
- means for determining respective voltage differences between the lowest voltage of the determined lowest battery cell and each respective voltage of each respective battery cell; and
- means for adjusting currents applied to the battery cells all at once during charging as a function of the respective voltage differences determined and a threshold value to provide balanced charging of the multiple series-connected battery cells, wherein the threshold value is a larger threshold value at a beginning of the charging process and a smaller threshold value as cell voltages increase.
20. A system as in claim 1 wherein the number of balancing bits are set all at once in a register to turn on or off respective balancing circuits reducing impact from a surge reading due to sudden changes in current.
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Type: Grant
Filed: Sep 18, 2009
Date of Patent: Dec 23, 2014
Patent Publication Number: 20110068744
Assignee: Schneider Electric IT Corporation (West Kingston, RI)
Inventor: Dao-Yi Zhu (Acton, MA)
Primary Examiner: Drew A Dunn
Assistant Examiner: Robert Grant
Application Number: 12/562,783
International Classification: H02J 7/00 (20060101);